Building construction



., y i R. B. Muss 2,202,745

' BUILDING CONSTRUCTION V Filed Ma roh 8 19:58 a Sheets-Sheet 1 Hh chenJr. Dining [Zoom /0 H Launclrg E; Shraqe Living Qoom INVENTOR.

A TTORNE Y R. B. MUSE- BUILDING CONSTRUCTION May 28, 1940.

Filed March 8, 19:58 6 Sheets-Sheet 2 INVENTOR. @ober/ 5. Muse A TTORNEY ,R; B. MUSE 2,202,745

. BUILDING consmuc'nou I Filed March 8, 938 s Sheets-Sheet a INVENTOR.Faber 5. Muse Q MQ arm M W]. VB 7.. W W

A TTORNEY M y 28; 1 0. R. B. MUSE ,202 74 BUILDlnG CONSTRUCTION FiledMarch 8, 1958 s Sheets-Sheet 4 Qoer/ 5. Muse 55' Q ZOQ @J-Zg 57-ATTORNEY 'R. a. MUSE BUILDING CONSTRUCTION May 28, 19 40.

v Filed March 8, 1938 e Sheets-Sheet 6 FILE FIE

I I u iv r I x I n A I k v 7/! I Ill/1474.4

v ATTORNEY Patented May 28, 1940 "PATENT OFFICE BUILDING CONSTRUCTIONRobert B. Muse, San Francisco, Calif., assignor to Barrett & Hilp,

. partnership consisting of J.

Harry H. Hilp.

San Francisco, Calif., a co- Frank Barrett and Application March 8,1938, Serial No. 194,573

5 Claims.

mortar. Furthermore a concrete block construction does not afford thestrength which is ordinarily associated with r'e-enforced concrete.Reenforced concrete walls poured as the building is being erected affordmaximum strength, but are likewise unsuited to low cost housing, becauseof the time and laborrequired for erection, and because of thewamount ofconcrete employed for a given area of wall. The use of pre-cast concretepanels has been proposed, as a substitute for smaller blocks, butinsofar as-I am aware, these panels are relatively expensive because ofthe steel framing required, and they involve considerable time andexpense for erection, due to the necessity of making connections betweenthe panels and with load bearing pilasters.

It is" an object of the present invention to provide a buildingconstruction which will gain all of the advantages of re -enforcedconcrete, but at a minimum of.cost for pre-iabrication and erection. Incarrying out the present invention I make use of pre-cast re-enforcedconcrete wall sections, which are devoid of expensive steel r framing,and which are directly coupled together to form the various walls andwall intersections.

The wall sections are relatively large in size, and t for houses of oneor two stories, they extend the full wall height.

A further object of the invention is to provide a novel type of joint.for the wall sections, whereby upon erection of the wall sections it ispossible to align them accurately, before the joint is made. permanentandrigid.

whereby pre-cast floor panels can be applied and attached to the wallsections. 5 Further objects of'the invention will appear from thefollowing description in which the preferred embodiment of the'inventionhas been set forth in detail in coniunctionwith the accompanyingdrawings Referring to the drawings:

and expense involved in laying the blocks with 1 Another object of theinvention is to facilitate Fig. 1 is a schematic lay-out; showing ahouse plan suitable for use with my construction, and involving variedjunctions between the wall sections. a

Fig. 2 is a perspective view, illustrating a pair of wall sectionsconstructed and. erected in. accordance with the present invention,together with pre-cast concrete floor and roof slabs."

Fig. 3 is a cross-sectional view taken along .the line 3-3 of Fig. 2.

Fig. 4 is a cross-sectional construction of the corner joint numberedthe house plan of Fig. 1.

Fig. 5 is an enlarged cross-sectional detail, illustrating theconstruction of the T-joint marked number 5 in the house plan of Fig. 1.a

Fig. 6 is an enlarged cross-sectional detail, illustrating the jointmarked number 6. in the house plan of Fig. 1, and involving a straightconnection between aligned wall sections.

Fig. 7 shows a T-intersection between wall sections, and correspondswith the joint I of Fig. 1.

, -Fig. 8 is an enlarged cross-sectional detail, showing a.cross-intersection corresponding to the joint numbered 8 of Fig. 1.

Fig. 9 is an enlarged cross-sectional detail, showing a T-intersectionbetween wall sections, and corresponding to the joint numbered 9 of Fig.1.

detail, 'showing the 4 in Fig. '10 is an enlarged cross-sectionaldetail,-

illustrating the manner in which floor slabs are attached to the wallsections.

Fig. 11 is an enlarged cross-sectional detail showing the manner inwhich the lower edges of the wall sections can be anchored to afoundation.

Fig. 12 is an enlarged cross-sectional detail showing the manner inwhicha window casing is formed in a wall section.

Fig. '13 is an enlarged cross-sectional detail showing a floor jointconstruction.

Fig. 14 is a side elevational view in cross-section, showing a modifiedform of wall section on a modified type of joint between wall sectionsand floor slabs. v

l ig. 15 is a side elevational view of the upper.-

most joint of.-Fig. 14, looking toward the inside sln'face oi the 'wallsections, with the. wall board I surfacing removed and with the floorslab in cross-section. r

Fig. 16 is a cross-sectional detail, showing a modified form of floorconstruction.

As illustrated in Figs. 1,. 2 and 3, my construction makes use ofre-enforced concrete wall sec} 9 tions II, which are pro-fabricated orpro-cast at sections are of a height extending from the foundation uponwhich they are erected, to a point above the roof deck. Where walls of atwo-story height are required, the wall sections extend the full twostories, to a point above the roof deck.

The wall sections for a building are not exact duplicates, except incertain instances where two or more duplicate sections may be employed.However, the majority of all the wall sections making up a completebuilding have certain features in common. Thus each of the two wallsections illustrated in Fig. 2 are formed with integral ribs Ii on theinner side of the wall, and extending in a vertical direction. At thelower end of each wall section there is a flange or rib 82, for engagingwith the foundation i3. Near the upper edge of each wall section thereis a flange or rib I8 which connects together the upper ends of ribs II,and which forms a ledge for supporting the roof deck I6. For wallsections which extend two stories in height, there is also a horizontal.rib H, which forms a ledge for supporting the second floor I 8. Thelower floor I 9 is carried by the foundation i3, as will be presentlyexplained. The vertical edges of the wall sections also have innerflanges or ribs, which are variously proportioned, according to the typeof joint with which it is to be used.

Wall sections such as described can be formed by. the use of suitablemolding equipment, involving the use of high frequency vibrators. Metalre-enforcement can be provided as is well known to those skilled in theart, in order to afford the desired degree of strength required.

Reference is made, by way of example, to the typical floor plan of ahouse, shown in Fig. i. This floor plan involves the use of the exteriorwall sections a, b, c, d, e, f, g, h, i, 7, and k, and the majorinterior partitions p, m, n, and 0. It also involves the use of certainjoint intersections, including particularly the intersections numbered 4to 9 inclusive.

Each of the various joint intersections Drovided, between the wallsections, are such that the walls can be initially connected together asthey are erected, whereby after such a connection is established, theconnections can be shifted to exact alignment. Thus the simple rightangle joint intersection numbered 4, illustrated in Figs. 3 and 4, makesuse of the wall sections I00. and I 07:. The adjacent edges of thesewall sections are provided with recesses 2| and 22 which aresubstantially in registry, and which form a common space extendingwithin the jointthe full height of the wall. The members serving to forman articulated connection between the two wall sections, include theU-shaped or .bail-like bars 23,. togetherwith bars 24 carried by'thewall section I0k. Bars 23 are disposed at spaced intervals along theheight of the section I 011, as shown in Fig. 3, and are embedded in theconcrete. .Bars 24 are loosely disposed within the holes 26 formed insection I070 and are retained by nuts 25.. They have free end portions21 which are bent downwardly, to engage within the bails 23. Beforeerecting the.

wall sections I01; and I070, the bars 24 are loosely apart, and suchspacing is retained after the sections have been properly aligned.Thereafter, to complete the joint, wedges 3i and 32, or some othersuitable form of obstructions, are applied to close the inner and outerfaces of the joint,-'after which the space provided by the recesses 2Iand 22 is fllled with cement mortar or grouting. After this cement hashardened a rigid point is formed, which is re-enforced by the steel bars23 and 24. Thereafter wedges 3| and 32 can be removed, and alny suitabletype of surfacing or troweling applied to enhance the appearance of thejoint.

Fig. fi'eorresponding to joint numbered 5 of Fig. 1, is in some respectssimilar to Fig. 4, but involves the intersection of an interiorpartition with-two outer wall sections. In this instance the twoadjacent edges of the aligned wall sec tions I0a and I0b, have recesses33, which together with the recess 35 of..wall section I011, form aspaceextending the entire wall height, within the joint. The outer wallsections are loosely connected together-by the bars 34, which extendthrough openings 36 in the concrete of the sections, and which havetheir ends threaded toreceive the nuts 31. Bars 34 are engaged by the Informing a joint of the type illustrated, in Fig. 4

5, wall sections I0a are first hoisted into place and connected togetherby means of the bars 34. Thereafter the inner partition I01) is erectedwith the bars 38 attached to the same, and as wall section I0p is placedin generally final position, the ends 42 of bars 38 are engagedjandinterlocked with bars 34. joint of Fig.4, the three wall sections can beshifted to secure proper alignment with respect wall sections disposedon' a common wall center.

In this case the two wall sections I01) and We are connected together bymeansfof the steel bars 44, corresponding to'the-bars 38 of Fig. 5.These bars are fitted loosely within the openings Now, as with the toeach other, and with respect to other parts of the building. Thereafterthe 45, and are threaded to receive the retention 1 nuts 41. Bolts 44are placed in position and the nuts 41 appl ed, after the 'two wallsections have been hoisted into position upon the foundation.

Thereafter, as with Figs}! and 5, the two all sections are shifted toproper aligned position, after which the spaces in the joint, formed bythe aligned recesses 48, are filled with cement mortar. Fig. 6 alsoserves to illustrate a type of joint which canbe used to insure againstleak- 'age. Thus in this instance, before fllling in recesses 46,- astrip 48 of compressed .expansible cork is inserted between the endfaces 40. Thei'e- 7i after the recesses 46 are filled in the same manneras Figs. 4 and 5. The exposed edge of the cork strip 48 can be coveredby any suitable form of portecting coating, such as paint, or a layer ofcement mortar. Compressed cork, by absorption of moisture, expands andforms a permanent liquid-tight seal between the fame, irrespective ofexpansion and contraction which may occur.

,Fig. 7' illustrates a T-intersection where one partition or exteriorwall intersects an intermediate part of an outer wall section. Thus inthis instance an intermediate part of wall secbars are likewise providedwith the down-turned end portions 28, to engage and interlock with thebails23. The filling of this joint with cement mortar is the same aswith, the other joints described; It can also be provided with the corksealing strip 48, the same as Fig. 6.

Fig. 8 illustrates a wall intersection, where the end edges of fourwalls terminate at a joint. In this instance interior partitions areinvolved, although a' similar type of joint might be used for exteriorwalls. Thus the panel sections I09 and I00 are loosely connected by thelateral steel bars 54, which have their ends threaded to receive theretention nuts 56. Wall sections Him and in are also loosely connectedby the bars 51,

which have their ends threaded to receive the retention nuts 58. Asviewed in plan the .bars 54 and 51 intersect at right angles. The endfaces of wall sections Him and In are spaced apart sufliciently far toamply clear the bars 54, while the adjacent end edges of panel sectionsHip and I00 are spaced apart a distance somewhat greater than thethickness of wall sections Him and In. Sections Him and in have recesses59 while the adjacent edges of sections I tip and I00 have recesses 6|,which are in communication with the former recesses through the spacing62, between sections Him and In. All of the communicating spaces-withinthe joint are then filled with cement mortar in the manner previouslydescribed, to form a rigid joint. Here again the joint as finally formedhas the cement mortar re-enforced by the steel'bars 54 and 51.

Fig. 9 illustrates a T-intersection, where the line of centers 0; theright-angle wall section is offset with respect to the center of thejoint between the other two sections.- Thus in this instance the wallsection lllk is formed similar to the wall section 1 0a ofFig. 4, exceptthat its end edge is formed with a recess 63. The adjacent edge ofwallsection I07 is likewise provided with a registering recess 64, andinitially the two sections Hlk and I07 are loosely connected by-the bars.66. Wall section lllkis provided with balls 23, the same as in Fig. 4,and which cooperate .with the bars 24 formed in the section Him. The

joint between sections Illk and Him can be finished the same as with Fi5, while that between sections lllk and I67 is substantially the same asinFig. 6.

With all of the wall sections it is desirable to employ means-tofacilitate applicationof an internal wall surfacing. Thus with thevarious wall sections, used in making the joint intersections describedwith respect to Figs. 4 to 9 inclu- -enforcements can be provided inconnection with bled, cement grouting is applied to the support- I asuitable filler 86 is applied in recess 84, to afsive, the sections areshown provided with inset wooden strips 68. 'To these strips suitablewall boarding 69 can be applied, or if desired other forms of wallsurfacing can be attached, as for example lath and plaster, or expandedmetal to 5 which the plaster can be applied. Corners, made by theinterior wall boards, can be finished in any desired manner, as by theuse of moulding strips cemented in place.

It is possible to use conventional types of floor and roofconstructions, that is, constructions making use of wood beams andconventional floor boarding. However, in keeping with the fire proofnature of the wall sections, I prefer to make use of floor slabs orpanels, formed of precast re-enforced concrete. For example, in Figs. 2,3 and 10, the roof deck i6 is formed of the two precast concrete slabs[6a and Hit). These slabs are provided with ribs or beams 12, on theirlower sides, and their edges rest upon and are supported by the ribs 14of the wall sections. To form a permanent connection between such slabsand the wall sections, an arrangement as shown in Fig. 10 can beemployed. Thus in this instance the edges of the slabs are providedwithpreformed openings 13, and when the wall sections are properly aligned,these openings register with openings 14, formed in' the flanges M ofthe wall sections. Suitable rethese openings, such as the U-shaped rodsor bars 15. After the slabs have been properly located, with hole 13 inregistry with holes.14, cement grouting can be poured into theseopenings, and then steel dowels 16 inserted, to form a permanentrigidconnection. With respect to alignment of the wall sections toproperly con- "nect with the floor and ceiling slabs, it may be pointedout that during erection of the wall sections, suitable templates can beapplied whereby the openings 14 are properly located, to accuratelyregister with the pre-formed slabs.

The number of slabs used in forming thefloor or ceiling deck, willdepend upon the size of the, slabs, and the area of the'floor or deck.Generally it is desirable for the slabs to extend completely across thefloor or ceiling area; with the longitudinal edges ofadjacent slabsslightly overlapping. Thus, in Fig. 2 the edge 11 of slab I611, rests;within the recess 19, formed in the slab I611.

The slabs forming the intermediate floor l8 can be substantially thesame as the roof deck l6. However, in this instance the sides of theslabs which engage the ledges H, are shown provided with extensions 8|,which are attached by dowels or pins to the ledges I1, in the samemanner as described in Fig. 10. The lower floor slabs I91; and I9!) canbe substantially the same as the slabs forming the roof deck. The edgesof this floor deck are shown directly supported by the foundation l3.

Fig. 13 illustrates a desirable form of joint between the longitudinaledges of adjacent floor slabs. In this instance, asthe slabs areassemingshoulder 82, and also between the adjacent edges of the slabs,as indicated at- The upper faces. of the two' slabs are also recessed asindicated at 84, and af erthe slabs are assembled 70 ford a smoothcontinuous floor surface. The filling 86 can be conveniently a strip oflinoleum or like composition, applied andretained in place by means of asuitable cement or adhesive.

Fig. 11 illustrates a convenient type of connecthrough openings I-orI09. Such joints can 'the door framing, or window frames, and areembedded in the proper sections at the time these sections are molded.As an example of this practice reference is made to Fig. 12. Here awindow opening 92 in one of the wall sections I0, is provided with asteel window frame 93, which is embedded in the concrete of the wallsections. Thus formed in the adjacent edges of after erection of suchwall sections it is. only necessary to apply the moving sash.

The outer surfaces of the walls can be treated in any desired manner, asfor example by painting, stucco, or a waterproof Portland cement wash.In general no particular exterior surface treatment is necessary, sincethe wall sections will possess smooth even textured surfaces. The innersurfaces of .the wall sections can be treated with inexpensive coatingmaterials, such as asphaltic emulsion. The floor surfaces can bestained, painted or otherwise treated as desired. For bath and kitchenfloors, or elsewhere if desired, the floor slabs can be given amonolithic Terrazzo finish 85 (Fig. 13). Preferably the Terrazzo mix isapplied to the floor slabs as a skim coat, after the concrete of theslab has initially set, but before setting is complete. After the slabshave been cured the surface is ground and polished.

. Figs. 14 and 15 show a modification in which the wall sections extendfor only'one story in height with the ends of the -wall'sectionsengaging fioor slabs. Thus in this instance the lower floor slabs 96rests upon the foundation, 91, and the wall sections .98 for the firststory of the building, rest upon the slabs 96. The floor slabs 99 forthe second story in turn have their edges interposed between the upperends of the lower wall sections 96 and the upper wall sections IN. Thejunctions between the end edgesof the wall sections, and the floor slabscan include the anchoring rods I02, extending from the foundation, andthe-tie bolts I03.for the upper floor decks. Also these junctions arefilled with grouting and are preferably provided with recesses, to befilled with grouting, in order to provide an interlock. Thus eachjunction between a wall section and a floor slab is shown provided withthe registering recesses I04 and I05. When a joint is initiallyestablished. a. suitable reenforcement be placed in the spaces providedby recesses I 04 and I05, and steel. wedges or like means are used tokeep the opposed faces separated a slight amount. After securing properalignment the spaces formed by recesses I 04 and Nine filled withgrouting I01, which can be introduced a fiat floor slab I I3. Suchseparate joists can be used with the arrangement of Fig. 10, or theirends may be disposed in recesses Ill and 5, wall sections II6andII1.

It will be evident from the above that my invention makes it possible toconstruct houses and other buildings at a minimum of cost, but offirst-class fire proof materials having a high degree of strength.Houses constructed in accordance with my plans require a minimumamountof expense for maintenance, and are subject to a minimum amount ofdeterioration. Erection of the 'main portions of the house, includingthe walls, inner partitions, and floors and ceiling, can be carried outin a minimum amount of time. The concrete wall sections and. also thefloor and ceiling slabs can be pre-formed to a high degree of accuracy,and as previously explained, the manner in which the walls l0 areconnected together and erected, makes it possible to have all of thewalls in exact alignment, for receiving, and interlocking with the floorand ceiling slabs. My invention is particularly applicable to largescale erection ofhouses, where a large number of houses are substantialduplicates,'and where they are to be erected in accordance with acommunity plan.

I claim:

1. In a building construction, a pair of upright wall sections formed ofpre-cast concrete, said sections being of a height at least equal to onestory of the building, adjacent edges of said sections, at a walljunction, being provided with recesses which are in substantial registryto form a space extending substantially the entire height of the wallsections, metal members serving to being of a height at least equal toonestory, and

metal members forming an articulated connection between the adjacentvertical edges of said wall sections, said members including laterallyextending bars attached to the vertical edges of said wall sections anddisposed within the inner and outer facesof the sections, said barsbeing adapted to directly interlock.

3. In a building construction, a pairof'vertically extending wallsections of pro-formed concrete, said sections being of a'height atleast' equal to one story of the building, rigid connecting membersextending laterally from the adja-- cent vertical edges of said wallsections, said connecting members being adapted to loosely interlock toforman articular connection between the two wall sections, the interlockbeing established by vertical movement of one wall section with respectto the other.

4. In a building construction, a pair of vertically extending wallsections, said sections being disposed at right angles'to each otherwhereby adjacent edges form a right-angle corner, re-

cesses formed inthe adjacent vertical edges of the wall sections, saidrecesses being substantially in registry whereby a space is formed inthe joint extending for substantially the entire height of the wallsections, a plurality of metal bars secured to said wall sections andhaving portions disposed in said space, said portions being in theformof bails, and a plurality of metal bars secured to the adjacent edgeof the other. wall section, said last named bars being adapted todirectly engage within said bails.

5. In a building'construction, at least two vertically extending wallsections, said wall sections being of a height at least equal to onestory, and means forming a temporary articulated connection between theadjacent vertical edges of said wall sections, said means includingrigid bars attached to the vertical edges of said wall sections, saidbars having portions extending into the space between said verticaledges, said portions being loosely interlocked, at least one set of saidbars for one wall section being loosely extended 5 through openings inthe wall section and being threaded to form draw bars.

.ROBEBT B. MUSE.

